Progressive Die Stamping for Different Materials: A Material Selection Guide

Progressive stamping is a precise, economical, high-volume automated metal forming technique that maintains product quality even at high production volumes. Progressive die stamping combines multiple processes into a single metal-forming process, enabling producers to create intricate products with the best metals for stamping without putting undue strain on the substrate or stopping output. 

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The complexity of the finished product and the qualities you want it to have are essential factors to consider when selecting the ideal progressive die-stamping materials. Here is the guide for material selection:

Factors to consider when choosing materials:

• Budget and material cost considerations:

The choice of material for metal stamping might be influenced by cost. For example, lower-performing materials are less expensive than metals and have excellent strength, formability, and resistance to corrosion. 

For the final product to be practical, affordable, and within the project budget, electronic part manufacturers must balance the necessary material properties and the total cost of the raw material.

• Formability and workability of the substance:

The smoothness and calibre of a product&#;s surface finish are determined by how well the metal can be machined. Processing metals that are easy to cut or shape is usually less expensive. In contrast, metals that are difficult to machine may need extra finishing or specialized tools to get the right outcome. 

Similarly, difficult weld metals may need extra preparation and process adjustments. In contrast, materials that are easy to weld require little work to produce products free of defects. 

• Strength and longevity prerequisites:

The durability and strength of the die and its components are essential to guarantee effective and economical production in progressive die stamping. Constructing the die precisely to ensure proper force alignment and distribution is essential. 

An incorrect force distribution or misalignment might cause early wear or failure. Tight tolerances during the production process guarantee that the parts fit together precisely, minimizing wear and tear.

Tool steels that have undergone proper heat treatment are harder and more resilient, which improves their capacity to bear stamping loads without deforming. The stamped component&#;s design should minimize sharp edges and other elements that could concentrate stress and cause die wear.

Common material used in progressive stamping:

• Steel:

Steel is a malleable progressive die-stamping material that is simple to shape and mold throughout the progressive stamping process. A wide range of geometries, including elaborate patterns and sophisticated features, can be produced using it. A wide variety of parts for various industries and applications can be produced because of this adaptability. 

Steel is used in applications that call for strong, durable parts because of its excellent strength-to-weight ratio. Because of steel&#;s strength, intricate parts with tight tolerances may be produced using progressive stamping, and the pieces are guaranteed to survive the pressures and forces applied during the process. 

Steel is a cost-effective material for progressive stamping since it is easily accessible and reasonably priced when considering other metals. 

• Aluminum alloys:

It is a solid option for pieces that compromise strength and workability and is frequently utilized for structural components.

When choosing an alloy for progressive stamping dies, consider the needed strength, corrosion resistance, and stamped part complexity. Specific properties of each alloy can influence the final product&#;s quality and performance.

• Copper alloys:

The special qualities of copper alloys make them popular for progressive die stamping. Heat and electricity are well-conducted via copper alloys, such as brass and bronze. Applications requiring effective electrical conductivity and heat dissipation will benefit from this. 

This is vital in progressive die stamping, where intricate geometries and accuracy are frequently needed.  Strong machinability is a characteristic of copper alloys that can result in improved surface finishes and reduced tool wear. 

Even while copper is not very hard by itself, it can be greatly strengthened while still having good toughness by alloying it with elements like zinc or tin. For high-stress applications, this qualifies it.

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• Brass:

Brass can be preferred in several applications due to its many benefits for progressive die stamping. Longer tool life and more efficient stamping processes can result from brass&#;s relative ease of machining and shaping. 
Brass is easily deformable without breaking because of its high flexibility. Because of this characteristic, complicated shapes can be produced with fewer flaws or cracks. Since stamped parts in these applications would be subjected to various environmental conditions, brass&#;s general good resistance to corrosion is advantageous. 
Brass can be made more versatile in stamping processes by alloying it with other metals to modify its characteristics for particular uses.

Wrapping it up:

Eigen is one of the top companies offering assembly, tooling, and metal stamping services. We encourage you to peruse our resource library to gain additional knowledge regarding the significance of meticulous material selection during manufacturing.  The core values of Eigen&#;s work ethic are quality, persistence, and valuable service. These are our main goals, and they influence every facet of our company.

The Progressive Die Process

Progressive die stamping offers a cost-effective and efficient method for producing large-volume runs by utilizing a progressive die. The die contains several stamping stations that perform unique forming operations as a strip of sheet metal is fed through the machine. Combining the necessary stamping tools into one die set improves the efficiency of the stamping project.

The following components are essential to a progressive die:

• Die Set
• Die Buttons (bushings)
• Punches
• Punch Holder
• Plate (section)
• Pins
• Slug Clearance
• Stripper

Progressive dies may also include features such as sub-liners, stop blocks, slides, or sensors. The primary goal of these components is to ensure accurate handling of the material.

Progressive metal stamping follows these steps:

1. The progressive die is positioned inside a reciprocating stamping press.
2. The press moves up, bringing the top die with it and allowing the metal strip to feed into the equipment.
3. When the press moves downward, the die closes to execute the stamping operation.
4. A finished part is released from the die with each stroke of the press.
5. The final cutoff station separates the finished parts from the conveying web.

Progressive Die Stamping vs. Transfer Press Stamping

Progressive die and transfer press stamping are similar operations that offer distinct advantages and disadvantages based on the specific demands of an application.

Progressive Die Stamping

In this process, a metal strip moves through a series of unique stamping stations to perform separate functions within a single machine. Each station alters the metal strip before it continues to the next station. The stock strip progressively takes on the desired shape and dimensions as it moves through the workstations. Precision throughout the entire operation is essential for total accuracy and effectiveness. Because all the parts are attached on one strip, this strip must be accurately positioned or all parts could be ruined.

Industries that benefit from progressive metal stamping include electronics, food and beverage, medical, appliances, military, automotive, and more. The process offers the following advantages for these industries:

• Improved Production Speeds
• Long Run Lengths
• Less Scrap Material
• Broader Design Freedom
• Increased Production Capacity
• Shorter Setup Times
• Higher Repeatability Rates
• Lower Production Costs
• Decreased Labor Costs
• Tight Tolerances

Transfer Press Stamping

This technique is the preferred stamping choice for large parts and applications with complex designs. In transfer press stamping, one press can operate multiple tools. Each part gets removed from the metal strip in the first station, allowing it to be freely shaped and transferred by each transfer die until completion.

Previously, these procedures required multiple manual transfers and presses, but automation has streamlined the transfer process into a single operation. Transfer press stations can produce the following:

• Threading
• Ribs
• Knurls
• Cutouts
• Pierced Holes

Transfer die stamping is ideal for low-volume production runs, offering better versatility and affordability when compared to progressive die stamping. Transfer die stamping can create complex geometries, intricate parts, and larger components with increased cost efficiency due to its lower tooling costs and reduction of scrap waste.

Industries enjoying the benefits of transfer die stamping include agriculture, automotive, electronic, medical, transportation, and more.

Progressive Die Stamping by Evans Metal Stamping

At Evans Metal Stamping, we offer high-quality progressive die stamping to meet the specific requirements of a broad range of applications and industries. We can deliver a high number of parts with a quick turnaround time, regardless of the complexity of the design, offering industry-leading stamping services for small, prototyping projects, high-volume production runs, and everything else in between.

Our precision metal stamping presses can reach top speeds of 1,200 strokes per minute and have stamping capacities that range between 30 and 1,000 tons. Partnering with Evans Metal Stamping provides customers with the following benefits:

• Decreased Lead Times
• Cost Savings
• Reduced Overall Supply Chain Risk
• Cyber Security Compliance
• Improved Communication
• Scalable Production
• Local And Secure U.S.-Based Supply Chain

Our other capabilities at Evans Metal Stamping include tool and die building, metal stamping, design engineering, welding and finishing, and machining services. Request a quote to get started on your progressive die stamping solution.

Want more information on progressive die design? Feel free to contact us.